Removal & Installation (Passenger/Cargo Van)
WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2002 GMC Savana Special, 2002 GMC Savana Camper Special, 2002 GMC Savana, 2002 GMC C3500 HD, and 2002 Chevrolet RV Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
- Disconnect negative battery cables. Drain the fuel from the tank. See FUEL TANK DRAINING PROCEDURE . Raise and support vehicle. Remove the off-road shield, if applicable. Loosen the filler neck hose clamp at the fuel tank. Disconnect the filler neck hose from the fuel tank. Support the fuel tank. Remove the fuel tank bolts, straps and the insulator strips, if applicable.
- Slightly lower the fuel tank and the fuel tank shield. Disconnect the fuel feed and the vapor hoses. Disconnect the electrical connections at the fuel sender assembly. Lower the fuel tank and the fuel tank shield. Use Fuel Sender Tool (J 36608) to remove the fuel sender assembly and the seal ring. Discard the old seal ring. Purge the tank, if the tank is being repaired.
- Install a NEW seal ring. Slightly raise the fuel tank and the fuel tank shield. Use the fuel sender tool in order to install the fuel sender assembly. To complete installation, reverse removal procedure. Tighten fasteners properly. See TORQUE SPECIFICATIONS . Inspect for leaks with the following procedure: Turn ignition ON for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for any fuel leaks.
NOTE:
Tighten the strap fasteners by steps, alternating between the fasteners, until the specified torque is reached. A failure to tighten the strap fasteners as specified will cause the bottom of the tank to flex upward. This will result in the fuel gauge indicating that there is fuel remaining in the tank when the tank is empty.